Finfet with dielectric isolation after gate module for improved source and drain region epitaxial growth

ABSTRACT

A method forming a semiconductor device that in one embodiment includes forming a gate structure on a channel region of fin structures, and forming a flowable dielectric material on a source region portion and a drain region portion of the fin structures. The flowable dielectric material is present at least between adjacent fin structures of the plurality of fin structures filling a space between the adjacent fin structures. An upper surface of the source region portion and the drain region portion of fin structures is exposed. An epitaxial semiconductor material is formed on the upper surface of the source region portion and the drain region portion of the fin structures.

BACKGROUND

1. Technical Field

The present disclosure relates to semiconductor devices, such assemiconductor devices including fin structures.

2. Description of the Related Art

The dimensions of semiconductor field effect transistors (FETs) havebeen steadily shrinking over the last thirty years or so, as scaling tosmaller dimensions leads to continuing device performance improvements.Planar FET devices typically have a conducting gate electrode positionedabove a semiconducting channel, and electrically isolated from thechannel by a thin layer of gate oxide. Current through the channel iscontrolled by applying voltage to the conducting gate. With conventionalplanar FET scaling reaching fundamental limits, the semiconductorindustry is looking at more unconventional geometries that willfacilitate continued device performance improvements. One such class ofdevice is a fin field effect transistor (finFET).

SUMMARY

In one aspect, a method is disclosed for forming a semiconductor devicethat includes forming a gate structure on a channel region of aplurality of fin structures. A flowable dielectric is then deposited ona source region portion and a drain region portion of the plurality offin structures, wherein the flowable dielectric is present at leastbetween adjacent fin structures of the plurality of fin structuresfilling a space between said adjacent fin structures. In a followingstep, an upper surface of the source region portion and the drain regionportion of the fin structures is exposed. An epitaxial semiconductormaterial is formed on the upper surface of the source region portion andthe drain region portion of the plurality of fin structures.

In another aspect, a method of forming a semiconductor device isprovided that includes forming a gate structure on a channel region of aplurality of fin structures. A dielectric layer is formed on a sourceregion portion and a drain region portion of the plurality of finstructures. A flowable dielectric is then deposited on the source regionportion and the drain region portion of the plurality of fin structuresover the dielectric layer. The flowable dielectric is present at leastbetween adjacent fin structures of the plurality of fin structuresfilling a space between the adjacent fin structures. In a followingstep, an upper surface of the source region portion and the drain regionportion of the fin structures is exposed by etching the dielectriclayer. The upper surface of the dielectric layer may then be recessed.An epitaxial semiconductor material is formed on the upper surface ofthe source region portion and the drain region portion of the pluralityof fin structures that has been recessed.

In another embodiment, a semiconductor device is provided that includesa gate structure present on a channel region portion of a plurality offin structures. A flowable dielectric is present filling the spacebetween adjacent fin structures in the plurality of fin structures.Epitaxial source and drain merge structures are present on an exposedupper surface of the fin structures, wherein the epitaxial source anddrain merge structures extend over the flowable dielectric that ispresent filling the space between adjacent fin structures.

BRIEF DESCRIPTION OF DRAWINGS

The following detailed description, given by way of example and is notintended to limit the disclosure solely thereto, will best beappreciated in conjunction with the accompanying drawings, wherein likereference numerals denote like elements and parts, in which:

FIG. 1 is a perspective cross-sectional view depicting forming a gatestructure on a plurality of fin structures, in accordance with oneembodiment of the present disclosure.

FIG. 2 is a perspective cross-sectional view depicting forming aflowable dielectric material being deposited on the source regionportion and the drain region portion of the plurality of fin structures,wherein the flowable dielectric is present at least between adjacent finstructures of the plurality of fin structures filling a space betweenthe adjacent fin structures, in accordance with one embodiment of thepresent disclosure.

FIG. 3 is a perspective cross-sectional view depicting forming a spaceron a sidewall of the gate structure, in accordance with one embodimentof the present disclosure.

FIG. 4 is a perspective cross-sectional view depicting recessing anupper surface of a fin structure, in accordance with one embodiment ofthe present disclosure.

FIG. 5 is a perspective cross-sectional view depicting one embodiment offorming a first epitaxial semiconductor material on the upper surface ofthe source region portion and the drain region portion of the finstructures having a p-type conductivity, in accordance with the presentdisclosure.

FIG. 6 is a perspective cross-sectional view depicting forming a secondepitaxial semiconductor material on the upper surface of the sourceregion portion and the drain region portion of the fin structures havingan n-type conductivity, in accordance with one embodiment of the presentdisclosure.

FIG. 7 is a perspective cross-sectional view depicting removing a blockmask from the first epitaxial semiconductor material after forming thesecond epitaxial semiconductor material, in accordance with oneembodiment of the present disclosure.

FIG. 8A is a cross-sectional side view parallel to a length of the gatestructure depicting the first epitaxial semiconductor material on thefin structure that is depicted in FIG. 7, in accordance with oneembodiment of the present disclosure.

FIG. 8B is a cross-sectional side view perpendicular to a length of thegate structure depicting a cross-section of the second epitaxialsemiconductor material on the fin structure that is depicted in FIG. 7,in accordance with one embodiment of the present disclosure.

FIG. 8C is a cross-sectional side view parallel to the length of thegate structure depicting the first and second epitaxial semiconductormaterials on the fin structures depicted in FIG. 7, in accordance withone embodiment of the present disclosure.

FIG. 9 is side cross-sectional view of another embodiment of anepitaxial material formed in accordance with the present disclosure,wherein the epitaxial material includes a buffer layer portion, a mainportion and a cap layer portion, in accordance with the presentdisclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Detailed embodiments of the claimed structures and methods are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely illustrative of the claimed structures and methods that maybe embodied in various forms. In addition, each of the examples given inconnection with the various embodiments are intended to be illustrative,and not restrictive. Further, the figures are not necessarily to scale,some features may be exaggerated to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the methods and structures of the present disclosure. Forpurposes of the description hereinafter, the terms “upper”, “lower”,“right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, andderivatives thereof shall relate to the embodiments of the disclosure,as it is oriented in the drawing figures. The terms “positioned on”means that a first element, such as a first structure, is present on asecond element, such as a second structure, wherein interveningelements, such as an interface structure, e.g. interface layer, may bepresent between the first element and the second element. The term“direct contact” means that a first element, such as a first structure,and a second element, such as a second structure, are connected withoutany intermediary conducting, insulating or semiconductor layers at theinterface of the two elements. As used herein, “semiconductor device”refers to an intrinsic semiconductor material that has been doped, thatis, into which a doping agent has been introduced, giving it differentelectrical properties than the intrinsic semiconductor. Doping involvesadding dopant atoms to an intrinsic semiconductor, which changes theelectron and hole carrier concentrations of the intrinsic semiconductorat thermal equilibrium. Dominant carrier concentration in an extrinsicsemiconductor determines the conductivity type of the semiconductor. Afield effect transistor (FET) is a semiconductor device in which outputcurrent, i.e., source-drain current, is controlled by the voltageapplied to a gate structure to the semiconductor device. A field effecttransistor has three terminals, i.e., gate structure, source region anddrain region. As used herein, a “fin structure” refers to asemiconductor material, which is employed as the body of a semiconductordevice, in which the gate structure is positioned around the finstructure such that charge flows down the channel on the two sidewallsof the fin structure and optionally along the top surface of the finstructure. A Fin Field Effect Transistor (FinFET) is a semiconductordevice that positions the channel region of the semiconductor device ina fin structure.

In some embodiments, the methods and structures disclosed hereinintroduce a flowable dielectric into the space separating adjacent finstructures after the gate module step of the process flow. In someembodiments, the flowable dielectric may be deposited so that it coversan entirety of the fin structures, wherein the flowable dielectric isrecessed following deposition so that the upper surface of the finstructure is exposed. Epitaxial semiconductor material may then be grownon the upper surface of the fin structures. In some embodiments, bycovering the lower part of the fin structure, the fin structure isprotected against contamination during the etch processes, such asreactive ion etch (RIE) processes, that are used to form the gatesidewall spacer. Further, by limiting the number of epitaxialsemiconductor crystal growth planes that are available, the methods andstructures that are disclosed herein allow for an epitaxial process withimproved performance, such as improved crystal quality or betterselectivity. Moreover, by forming a layered epitaxial semiconductormaterial that includes a buffer layer portion, a main portion and a caplayer portion, improved control can be gained over critical deviceparameters, such as junction profile and resistance. In someembodiments, by constraining the epitaxial growth so that thesemiconductor material does not extend down the sidewalls of the finstructures, the methods and structures disclosed herein may limit thesource and drain region to gate capacitance. The methods and structuresof the present disclosure are now discussed with more detail referringto FIGS. 1-9.

FIG. 1 depicts one embodiment of forming gate structures 10 on aplurality of fin structures 15. The material that provides the finstructures 15 may be a silicon-containing material, such as singlecrystal silicon (Si), monocrystalline silicon (Si), polycrystallinesilicon (Si) or a combination thereof. In some embodiments, the finstructure 15 may be formed from a semiconductor on insulator (SOI)substrate, in which the upper layer of the SOI substrate, i.e., SOIlayer, provides the material for the fin structures 15, and the burieddielectric layer of the SOI substrate provides the material for thedielectric surface 5 that the fin structures 15 are present on. In someembodiments, in which an SOI substrate is used for forming the finstructures 15 and the dielectric surface 5, a base semiconductorsubstrate (not shown) may be present underlying the material layer thatprovides the dielectric surface 5. The base semiconductor substrate maycomprise at least one of Si, Ge, SiGe alloys, SiGe:C, SiC, Si:C, GaAs,InAs, InP, as well as other III/V or II/VI compound semiconductors. Thebase semiconductor substrate is optional, and may be omitted. In otherembodiments, the fin structures 15 and the dielectric surface 5 can beformed using a bulk semiconductor substrate or a dielectric isolatedwafer. It is noted that the above description of substrates suitable forforming the fin structure 15 and the dielectric surface 5 are providedfor illustrative purposes only, and are not intended to limit thepresent disclosure. For example, the fin structures 15 and thedielectric surface 5 may be provided by any arrangement that provides asemiconductor material that is present on a dielectric surface 5 so thatthe semiconductor material may be processed to provide the finstructures 15.

The fin structures 15 may be formed using photolithography and etchprocesses. For example, the fin structures 15 may be formed usingsidewall image transfer (SIT) methods. More specifically, in one exampleof a SIT method, a photoresist mandrel is first formed on a surface ofthe semiconductor material of the substrate that is processed to providethe fin structures 15, e.g., etching the SOI layer of an SOI substrate.The photoresist mandrel may be formed using deposition, patterning anddevelopment processes. Thereafter, a low-pressure chemical vapor(isotropic) deposition provides a dielectric profile on the sidewalls ofthe photoresist mandrel. The photoresist mandrel may then be removed.For example, photoresist mandrel can be removed using a chemical stripor selective etching. Following removal of the photoresist mandrel, thedielectric profile remains to provide an etch mask. The semiconductormaterial is then etched using the dielectric profile as an etch mask toprovide the fin structures 15. The etch process for forming the finstructures 15 may be an anisotropic etch, such as reactive ion etching(RIE). In the embodiments that employ an SOI substrate to provide thefin structures 15, the etch process may be continued until an entirethickness of the SOI layer is removed so that the portions of the SOIlayer that are not etched provide the fin structures 10.

In some embodiments, each of the fin structures 15 may have a height H₁ranging from 5 nm to 200 nm. In another embodiment, each of the finstructures 15 has a height H₁ ranging from 10 nm to 100 nm. In oneexample, each of the fin structures 15 may have a height H₁ ranging from20 nm to 60 nm. Each of the fin structures 15 may have a width W₁ ofless than 20 nm. In another embodiment, each of the fin structures 5 hasa width W₁ ranging from 3 nm to 12 nm. The pitch P1 separating adjacentfin structures 15 may range from 10 nm to 500 nm. In another example,the pitch P1 separating adjacent fin structures 15 may range from 20 nmto 50 nm.

FIG. 1 further depicts one embodiment of forming a gate structure 10 ona channel portion of the fin structures 15. The gate structure 10functions to switch the semiconductor device from an “on” to “off”state, and vice versa. The gate structure 10 typically includes at leastone gate dielectric (not shown) and at least one gate conductor 8. Theat least one gate dielectric may be composed of an insulator, and ispresent around the channel region of the fin structure 15, and the atleast one gate conductor 8 is composed of an electrically conductivematerial, and is present on at least one gate dielectric. A gatedielectric cap 9 may be present atop the at least one gate conductor 8.

The gate structure 10 may be formed by forming blanket material layersfor the at least one gate dielectric, the at least one gate conductor 8,and the at least one gate dielectric cap 9 to provide a gate stack, andpatterning and etching the gate stack to provide the gate structure 10utilizing photolithography and etch process steps. The photolithographyand etch processes for forming the gate structure 10 is similar to thephotolithography and etch processes that have been described above forforming the fin structures 15.

The at least one gate dielectric is typically positioned on at least aportion of the upper surface and sidewall of the fin structure 15. Theat least one gate dielectric may be formed by a thermal growth processsuch as, e.g., oxidation, nitridation or oxynitridation, or may beformed using a deposition process, such as chemical vapor deposition(CVD). In some embodiments, the at least one gate dielectric is composedof a high-k dielectric material. High-k dielectric materials have adielectric constant greater than silicon oxide (SiO₂) at roomtemperature, e.g., 25° C. For example, a high-k dielectric composed ofhafnium oxide (HFO₂) may have a dielectric constant of 16.0 or greater.The physical thickness of the at least one gate dielectric may vary, buttypically, the at least one gate dielectric has a thickness ranging from1 nm to 10 nm.

The at least one gate conductor 8 may be composed of polysilicon,silicon germanium (SiGe), a silicide, a metal or ametal-silicon-nitride, such as Ta—Si—N. Examples of metals that can beused as the at least one gate conductor 8 include, but are not limitedto Al, W, Cu, Ti or other like conductive metals. The physical thicknessof the at least one gate conductor 8 may range from 5 nm to 100 nm. Thegate dielectric cap 9 may be composed of a nitride, oxide, oxynitridematerial, and/or any other suitable dielectric layer.

In the process flow provided in the supplied figures, the gate structure10 is formed using a gate first process flow. In a gate first processflow, the gate structure 10 is formed prior to forming the source anddrain regions. Although not depicted in the supplied figures, a gatelast process flow is equally applicable to the present disclosure. In agate last process flow, a sacrificial gate structure, i.e., replacementgate structure, is formed prior to forming the source and drain regions,wherein the replacement gate structure defines the geometry of the laterformed functional gate structure. In a gate last process flow, followingthe formation of the source and drain regions, the replacement gatestructure is removed, and a functional gate structure is formed in itsplace.

Still referring to FIG. 1, in some embodiments, a dielectric layer 20may be deposited on the exposed portions of the fin structures 15. Thedielectric layer 20 may be blanket deposited on the fin structures 15and the portion of the dielectric surface 5 that is present betweenadjacent fin structures 15. The dielectric layer 20 is typicallycomposed of an oxide, oxynitride or nitride material, but otherdielectric materials are equally suitable for the dielectric layer 20.For example, the dielectric layer 20 may be composed of silicon oxide orsilicon oxynitride. The dielectric layer 20 typically has a conformalthickness, and is deposited using a conformal deposition process. Theterm “conformal” denotes a layer having a thickness that does notdeviate from greater than or less than 30% of an average value for thethickness of the layer. In one embodiment, the thickness of thedielectric layer 20 may range from 2 nm to 20 nm. In another embodiment,the thickness of the dielectric layer 20 may range from 3 nm to 10 nm.It is noted that the above description for the thickness of thedielectric layer 20 is provided for illustrative purposes only, and isnot intended to limit the present disclosure, as other thicknesses havealso been contemplated for use herein.

The dielectric layer 20 may be deposited using a chemical vapordeposition (CVD) method. Chemical vapor deposition (CVD) is a depositionprocess in which a deposited species is formed as a result of chemicalreaction between gaseous reactants at greater than room temperature (25°C. to 900° C.); wherein solid product of the reaction is deposited onthe surface on which a film, coating, or layer of the solid product isto be formed. Variations of CVD processes include, but not limited to,Atmospheric Pressure CVD (APCVD), Low Pressure CVD (LPCVD) and PlasmaEnhanced CVD (PECVD), Metal-Organic CVD (MOCVD) and combinations thereofmay also be employed. The dielectric layer 20 may also be formed usingthermal growth processes, such as thermal oxidation.

FIG. 2 depicts one embodiment of forming a flowable dielectric material25 being deposited over the source region portion and the drain regionportion of the plurality of fin structures 15 and over the dielectriclayer 20, wherein the flowable dielectric material 25 is present atleast between adjacent fin structures of the plurality of fin structures15 filling a space between the adjacent fin structures 15. The flowabledielectric material 25 may be an oxide, such as silicon oxide. It isnoted that the composition for the flowable dielectric material is notlimited to only oxides, as other dielectric materials may also besuitable for the flowable dielectric material 25. For example, theflowable dielectric material 25 may be composed of a low-k dielectricmaterial. In some examples, the low-k dielectric that provides theflowable dielectric material 25 may have a dielectric constant of 4.0 orless (measured at room temperature, e.g., 25° C., and 1 atm). Forexample, a low-k dielectric material suitable for the flowabledielectric material 25 may have a dielectric constant ranging from about1.0 to about 3.0. Examples of low-k materials suitable for the flowabledielectric material 25 include organosilicate glass (OSG), fluorinedoped silicon dioxide, carbon doped silicon dioxide, porous silicondioxide, porous carbon doped silicon dioxide, spin-on organic polymericdielectrics (e.g., SILK™), spin-on silicone based polymeric dielectric(e.g., hydrogen silsesquioxane (HSQ) and methylsilsesquioxane (MSQ), andcombinations thereof.

The flowable dielectric material 25 is typically formed using spin onglass (SOG) deposition and flowable chemical vapor deposition (FCVD).Spin on glass (SOG) compositions typically includes silicon oxide (SiO₂)and optionally dopants (either boron or phosphorous) that is suspendedin a solvent solution. The SOG is applied the deposition byspin-coating. Spin-coating is a process used to coat the depositionsurface with material which is originally in the liquid form, whereinthe liquid is dispensed onto the deposition surface in predeterminedamount, and the wafer is rapidly rotated. For example, the depositionsurface, e.g., substrate, may be rotated, i.e., spun, to speeds as greatas 6,000 rpm. During spinning, liquid is uniformly distributed on thesurface by centrifugal forces. The deposited material may then besolidified by a low temperature bake, e.g., baking at temperatures lessthan 200° C.

The flowable dielectric material 25 may also be deposited using flowablechemical vapor deposition (FCVD). The flowable dielectric material 25deposited by flowable chemical vapor deposition (FCVD) may be asubstantially carbon free silicon oxide (SiO₂) material. Flowablechemical vapor deposition (FCVD) provides for a liquid-like film thatflows freely into trench like geometries to provide a bottom up,void-free and seam-free fill. Flowable chemical vapor deposition canfill gaps having aspect ratios of up to 30:1. One example, of a flowablechemical vapor deposition process is available from Applied Materialsunder the tradename Eterna FCVD system.

The flowable dielectric material 25 may be formed deposited to a heightthat is less than the height of the fin structures 15, or the flowabledielectric material 25 may be deposited to cover the fin structures 15,wherein the flowable dielectric material 25 may be later recessed usingan etch process to expose the upper surfaces of the fin structures 15.The etch process for recessing the flowable dielectric material 25 maybe an anisotropic etch, such as reactive ion etch (RIE).

FIG. 3 depicts forming a gate sidewall spacer 30 on a sidewall of thegate structure 10. In one embodiment, the gate sidewall spacer 30 may beformed by using a blanket layer deposition, such as chemical vapordeposition (CVD), and an anisotropic etchback method. The gate sidewallspacer 30 may have a width ranging from 2.0 nm to 15.0 nm, and may becomposed of a dielectric, such as a nitride, oxide, oxynitride, or acombination thereof. In one example, the gate sidewall dielectric spacer30 is composed of silicon oxide (SiO₂). The flowable dielectric material25 protects the sidewalls and lower portion of the fin structures 15from being damages by the etch process that forms the gate sidewallspacer 30.

FIG. 3 also depicts removing the dielectric layer 20 from the uppersurface of at least one of the fin structures 15. The dielectric layer20 may be removed by an etch that is selective to the gate sidewallspacer 30, and the flowable dielectric material 25. The term “selective”as used to describe a material removal process denotes that the rate ofmaterial removal for a first material is greater than the rate ofremoval for at least another material of the structure to which thematerial removal process is being applied. For example, in oneembodiment, a selective etch may include an etch chemistry that removesa first material selectively to a second material by a ratio of 100:1 orgreater. The etch process for removing the exposed portions of thedielectric layer 20 may be an anisotropic etch or an isotropic etch. Insome examples, the etch process may be a wet chemical etch, reactive ionetch (RIE), plasma etch, laser etch and combinations thereof. In someembodiments, the dielectric layer 20 may remain on the upper surface ofsome of the fin structures 15 by protecting those fin structures 15 witha etch mask, such as a photoresist mask 16.

FIG. 4 is a perspective cross-sectional view depicting one embodiment ofrecessing an upper surface of a fin structure 15 a. In the embodimentthat is depicted in FIG. 4, the fin structures 15 a being recessed arethe fin structures 15 a for semiconductor devices processed to have ap-type conductivity, e.g., p-type fin field effect transistors (p-typeFinFETs). By p-type it is meant that the source and drain regionportions of the fin structures 15 a have been doped with a p-typeconductivity dopant. As used herein, the term “drain region” means adoped region in semiconductor device located at the end of thefunctional channel region, in which carriers are flowing out of thetransistor through the drain region. The term “source region” is a dopedregion in the semiconductor device, in which majority carriers areflowing into the channel region. P-type conductivity source and drainregions may be produced in a fin structure 15 a of a type IVsemiconductor, such as a silicon including semiconductor or a germaniumincluding semiconductor, by doping the type IV semiconductor materialwith group III-A elements of the periodic table of elements, such asboron (B).

The upper surface of the fin structures 15 a for the p-type FinFETs maybe recessed using an anisotropic etch process, such as reactive ion etch(RIE). Other etch processes for recessing the upper surface of the finstructures 15 a may include plasma etching or laser etching. In someembodiments, in which the structure is being processed to provide p-typeFinFETs and n-type FinFETs simultaneously on the same substrate, such asin a complementary metal oxide semiconductor (CMOS) arrangement, some ofthe fin structures 15 b may be protected from being etched by an etchmask 16. For example, as depicted in FIGS. 3 and 4, an etch mask 16 maybe present over the fin structures 15 b that are subsequently processedto provide an n-type conductivity semiconductor device, such as ann-type FinFET. By “n-type” it is meant that the source and drain regionportions of the fin structures 15 b have been doped with an n-typeconductivity dopant. An n-type conductivity may be produced in finstructure 15 b composed of a type IV semiconductor, such as a siliconincluding semiconductor or a germanium including semiconductor, bydoping the type IV semiconductor material with group V elements of theperiodic table of elements, such as phosphorus (P) or arsenic (As).

It is noted that the recessing of the fin structures 15 a depicted inFIG. 4 is optional. The step of recessing the fin structures 15 a may beomitted.

FIG. 5 depicts one embodiment of forming a first epitaxial semiconductormaterial 35 a on the upper surface of the source region portion and thedrain region portion of the fin structures 15 a having a p-typeconductivity. The first epitaxial semiconductor material 35 a istypically formed using an epitaxial growth and/or deposition process.“Epitaxial growth and/or deposition” means the growth of a semiconductormaterial on a deposition surface of a semiconductor material, in whichthe semiconductor material being grown has substantially the samecrystalline characteristics as the semiconductor material of thedeposition surface. An epitaxial material is a material that has beendeposited using an epitaxial deposition process, and therefore has thecharacteristics of an epitaxially deposited material, such as having thesubstantially the same crystalline characteristics as the semiconductormaterial of the deposition surface. In some embodiments, when thechemical reactants are controlled and the system parameters setcorrectly, the depositing atoms of an epitaxial deposition processarrive at the deposition surface with sufficient energy to move aroundon the surface and orient themselves to the crystal arrangement of theatoms of the deposition surface. For example, an epitaxial filmdeposited on a {100} crystal surface will take on a {100} orientation.

Typically, the epitaxial growth and/or deposition process that providesthe first epitaxial semiconductor material 35 a is a selectivedeposition process that will not deposit the epitaxial material ondielectric surfaces, such as the etch mask 16 that is present over thefin structures 15 b that are subsequently processed to provide a p-typeFinFET.

The first epitaxial semiconductor material 35 a may be a type IVsemiconductor material, such as a silicon including material, or may bea compound semiconductor, such as a type III-V semiconductor material.For example, when the first epitaxial semiconductor material 35 a is atype IV semiconductor material, the first epitaxial semiconductormaterial 35 a may be silicon, single crystal silicon, multicrystallinesilicon, polycrystalline silicon, silicon doped with carbon (Si:C),germanium (Ge), silicon germanium (SiGe), silicon germanium doped withcarbon (SiGe:C) and combinations thereof. In some cases a silicongermanium tin material (SiGeSb) may be used to further tune the crystallattice and electrical properties of the epitaxial film. When the firstepitaxial semiconductor material 35 a is a compound semiconductor, suchas a type III-V semiconductor material, the compound semiconductormaterial may be selected from the group consisting of aluminumantimonide (AlSb), aluminum arsenide (AlAs), aluminum nitride (AlN),aluminum phosphide (AlP), gallium arsenide (GaAs), gallium phosphide(GaP), indium antimonide (InSb), indium arsenic (InAs), indium nitride(InN), indium phosphide (InP), aluminum gallium arsenide (AlGaAs),indium gallium phosphide (InGaP), aluminum indium arsenic (AlInAs),aluminum indium antimonide (AlInSb), gallium arsenide nitride (GaAsN),gallium arsenide antimonide (GaAsSb), aluminum gallium nitride (AlGaN),aluminum gallium phosphide (AlGaP), indium gallium nitride (InGaN),indium arsenide antimonide (InAsSb), indium gallium antimonide (InGaSb),aluminum gallium indium phosphide (AlGaInP), aluminum gallium arsenidephosphide (AlGaAsP), indium gallium arsenide phosphide (InGaAsP), indiumarsenide antimonide phosphide (InArSbP), aluminum indium arsenidephosphide (AlInAsP), aluminum gallium arsenide nitride (AlGaAsN), indiumgallium arsenide nitride (InGaAsN), indium aluminum arsenide nitride(InAlAsN), gallium arsenide antimonide nitride (GaAsSbN), gallium indiumnitride arsenide aluminum antimonide (GaInNAsSb), gallium indiumarsenide antimonide phosphide (GaInAsSbP), and combinations thereof. Itis noted that the above examples of compositions for the epitaxialmaterial that provide the in situ doped semiconductor material 10 areprovided for illustrative purposes only, and are not intended to belimitation. Other material compositions may be equally suitable for usewith the present disclosure.

In some embodiments, when the fin structures 15 a are being processed toprovide a p-type FinFET, the first epitaxial semiconductor material 35 amay be composed of silicon and germanium including material, such assilicon germanium. In some embodiments, in which the semiconductormaterial that forms the first epitaxial semiconductor material 35 a iscomposed of silicon (Si) and germanium (Ge), the silicon sources forepitaxial deposition may be selected from the group consisting ofsilane, disilane, trisilane, tetrasilane, hexachlorodisilane,tetrachlorosilane, dichlorosilane, trichlorosilane, methylsilane,dimethylsilane, ethylsilane, methyldisilane, dimethyldisilane,hexamethyldisilane and combinations thereof, and the germanium gassources may be selected from the group consisting of germane, digermane,halogermane, dichlorogermane, trichlorogermane, tetrachlorogermane andcombinations thereof. It is noted that the above examples of sourcegasses for deposition of epitaxial material are provided forillustrative purposes only, and are not intended to be limitation. Otherdeposition source gasses may be equally suitable for use with thepresent disclosure.

In some embodiments, forming a silicon germanium (SiGe) first epitaxialsemiconductor material 35 a on a silicon upper surface of the finstructures 15 a produces a compressive strain in the channel region ofthe p-type FinFET that increases hole carrier mobility. Increasing holecarrier mobility increases switching speed for p-type FinFET devices. Inthe embodiments, in which the upper surface of the fin structures 15 ahas been recessed, the silicon germanium first epitaxial semiconductormaterial 35 a is brought into closer proximity to the channel region ofthe fin structures 15 a, which further increases the amount ofcompressive strain that is induced upon the channel region of thedevice.

In some embodiments, the first epitaxial semiconductor material 35 a maybe doped, wherein the dopant may be introduced to the first epitaxialsemiconductor material 35 a using an in-situ doping process. In theembodiments, in which the fin structures 15 a are processed to providep-type FinFETs, the first epitaxial semiconductor material 35 a may bedoped to a p-type conductivity. By “in-situ” it is meant that the dopantthat dictates the conductivity type, i.e., n-type or p-type, of thesemiconductor material is introduced during the process step that formsthe semiconductor material. For example, the dopant that dictates theconductivity type of the first epitaxial semiconductor material 35 a maybe introduced during the epitaxial deposition process that forms thematerial layer for the first epitaxial semiconductor material 35 a. Thep-type gas dopant source employed in the epitaxial deposition processfor forming the first epitaxial semiconductor material 35 a may includediborane (B₂H₆). In some embodiments, an anneal process may drive thedopant, e.g., p-type dopant, from the first epitaxial semiconductormaterial into the source and drain region portions of the fin structure15 a.

The thickness of the first epitaxial semiconductor material 35 a mayrange from 5 nm to 100 nm, depending on structural constraints and thedimensions of the fin and gate. Preferentially the thickness of thefirst epitaxial layer is between 10 nm to 50 nm.

In some embodiments, the first epitaxial semiconductor material 35 a mayextend from the upper surface of a first fin structure 15 a over andatop the flowable dielectric material 25 into contact with the uppersurface of an adjacent fin structure 15 a to provide an epitaxial finmerge structure, as depicted in FIG. 5. It is noted that embodimentshave been contemplated that includes a first epitaxial semiconductormaterial 35 a for each fin structure 15 a that does not contact theiradjacent fin structures.

FIG. 6 depicts forming a second epitaxial semiconductor material 35 b onthe upper surface of the source region portion and the drain regionportion of the fin structures 15 b that are subsequently processed toprovide n-type FinFETs. In some embodiments, prior to forming the secondepitaxial semiconductor material 35 b, a block mask 17, such as aphotoresist mask, may be formed over the fin structures 15 a that areprocessed to provide the p-type FinFET. The block mask 17 obstructs thesecond epitaxial material 35 b from being formed on the first epitaxialmaterial 35 a.

Similar to the first epitaxial semiconductor material 35 a, the secondepitaxial semiconductor material 35 b may be composed of a type IVmaterial, such as silicon, germanium, or silicon germanium, or acompound semiconductor, such as a type III-V semiconductor material,e.g., GaAs. Therefore, the above descriptions for the semiconductormaterial for the first epitaxial semiconductor material 35 a is suitablefor the description of the materials that may be suitable for the secondepitaxial semiconductor material 35 b.

In some embodiments, when the fin structures 15 b are being processed toprovide n-type FinFETs, the second epitaxial semiconductor material 35 bmay be composed of silicon or silicon doped with carbon (Si:C) material.In some embodiments, in which the semiconductor material that forms thesecond epitaxial semiconductor material 35 b is composed of silicon(Si), the silicon sources for epitaxial deposition may be selected fromthe group consisting of silane, disilane, trisilane, tetrasilane,hexachlorodisilane, tetrachlorosilane, dichlorosilane, trichlorosilane,methylsilane, dimethylsilane, ethylsilane, methyldisilane,dimethyldisilane, hexamethyldisilane and combinations thereof. When thesecond epitaxial semiconductor material 35 b is composed of silicondoped with carbon, a carbon source may be added to deposition chamberwith the above described silicon sources. Carbon sources, i.e., carboncontaining precursors, that are useful to deposit silicon containingcompounds include organosilanes, alkyls, alkenes and alkynes of ethyl,propyl and butyl. Such carbon sources include methylsilane (CH₃SiH₃),dimethylsilane ((CH₃)₂SiH₂), ethylsilane (CH₃CH₂SiH₃), methane (CH₄),ethylene (C₂H₄), ethyne (C₂H₂), propane (C₃H₈), propene (C₃H₆), butyne(C₄H₆), as well as others. The carbon (C) content of the epitaxial grownsilicon doped with carbon (Si:C) may range from 0.3% to 5%, by atomicweight %. In another embodiment, the carbon content of the epitaxialgrown silicon doped with carbon (Si:C) may range from 1% to 2%. Otherdeposition source gasses may be equally suitable for use with thepresent disclosure.

In some embodiments, forming a second epitaxial semiconductor material35 b composed of silicon doped with carbon (Si:C) on a silicon uppersurface of the fin structures 15 b produces a tensile strain in thechannel region of the n-type FinFET that increases electron carriermobility. Increasing electron carrier mobility increases switching speedfor n-type FinFET devices. In the embodiments, in which the uppersurface of the fin structures 15 b has been recessed, the secondepitaxial semiconductor material 35 b is brought into closer proximityto the channel region of the fin structures 15 b, which furtherincreases the amount of tensile strain that is induced upon the channelregion of the device.

In some embodiments, the second epitaxial semiconductor material 35 bmay be doped, wherein the dopant is introduced to the second epitaxialsemiconductor material 35 b using an in-situ doping process. In theembodiments, in which the fin structures 15 b are processed to providen-type FinFETs, the first epitaxial semiconductor material 35 a may bedoped to an n-type conductivity. In one embodiment, the n-type gasdopant source may include arsine (AsH₃), phosphine (PH₃) andalkylphosphines, such as with the empirical formula R_(x)PH_((3-x)),where R=methyl, ethyl, propyl or butyl and x=1, 2 or 3. Alkylphosphinessuitable for use with the present disclosure include trimethylphosphine((CH₃)₃P), dimethylphosphine ((CH₃)₂PH), triethylphosphine ((CH₃CH₂)₃P)and diethylphosphine ((CH₃CH₂)₂PH). In some embodiments, an annealprocess may drive the dopant, e.g., n-type dopant, from the secondepitaxial semiconductor material 35 b into the source and drain regionportions of the fin structure 15 b.

The thickness of the second epitaxial semiconductor material 35 b mayrange from 5 nm to 100 nm, depending on structural constraints and thedimensions of the fin and gate. Preferentially the thickness of thefirst epitaxial layer is between 10 nm to 50 nm.

In some embodiment, the second epitaxial semiconductor material 35 b mayextend from the upper surface of a first fin structure 15 a, 15 b overand atop the flowable dielectric material 25 into contact with the uppersurface of an adjacent fin structure 15 a, 15 b to provide an epitaxialfin merge structure, as depicted in FIG. 6. It is noted that embodimentshave been contemplated that include a second epitaxial semiconductormaterial 35 b for each fin structure 15 b that does not contact theiradjacent fin structures.

FIG. 7 depicts removing the block mask 17 from the first epitaxialsemiconductor material 35 a after forming the second epitaxialsemiconductor material 35 b. The block mask 17 may be removed usingselective etching or chemical stripping.

In the embodiments in which the gate structures 10 to the device areformed using a gate last process flow, the sacrificial gate structure(also referred to as replacement gate structure) may be removed at thisstage of the process flow. More specifically, an interlevel dielectriclayer (not shown) may be blanket deposited over the structure depictedin FIG. 7 and planarized to expose an upper surface of the sacrificialgate structure. The sacrificial gate structure may then be removed usingan etch that is selective to the interlevel dielectric layer, the gatesidewall spacers 30 and the channel region portions of the finstructures 15 a, 15 b. A functional gate structure including at leastone gate dielectric and at least one gate conductor may then be formedin the space provided by removing the sacrificial gate structure. Thefunctional gate structure typically includes at least one gatedielectric that is present on the channel region portions of the finstructures 15 a, 15 b, and at least one gate conductor on the at leastone gate dielectric.

FIG. 7 depicts one embodiment of a semiconductor device that includes agate structure 10 present on a channel region portion of a plurality offin structures 15 a, 15 b. A flowable dielectric 25 is present fillingthe space between adjacent fin structures 15 a, 15 b. Epitaxial sourceand drain merge structures 35 a, 35 b are present on an exposed uppersurface of the fin structures 15 a, 15 b. The epitaxial source and drainmerge structures 35 a, 35 b extend over the flowable dielectric material25 that is present filling the space between adjacent fin structures 15a, 15 b.

FIG. 8A is a perspective cross-sectional side view of the fin structure15 b of the n-type FinFET that is parallel to a length of the gatestructure 10. FIG. 8a depicts a second epitaxial semiconductor material35 b on the upper surface of the fin structure 15 b. FIG. 8b is aperspective cross-sectional side view of the fin structure 15 a of thep-type FinFET parallel to a length of the gate structure 10. FIG. 8bdepicts a first epitaxial semiconductor material 35 a on the uppersurface of the fin structure 15 a. FIG. 8B depicts that the uppersurface of the fin structure 15 a that the first epitaxial semiconductormaterial 35 a is present on is recessed from the upper surface of thechannel region portion of the fin structure 15 a by a dimension D1ranging from 1 nm to 100 nm. In another example, the upper surface ofthe fin structure 15 a that the first epitaxial semiconductor material35 a is present on is recessed from the upper surface of the channelregion portion of the fin structure 15 b by a dimension D1 ranging from20 nm to 40 nm. FIG. 8C is a perspective cross-sectional side viewperpendicular to the length of the gate structures 10 depicting thefirst and second epitaxial semiconductor materials 35 a, 35 b on the finstructures 15 a, 15 b that is depicted in FIG. 7.

In some embodiments, the methods and structures disclosed hereinintroduce a flowable dielectric material 25 into the space separatingadjacent fin structures 15 a, 15 b. In some embodiments, by covering thelower part of the fin structures 15 a, 15 b, the fin structures 15 a, 15b are protected against contamination from the etch processes, such asreactive ion etch (RIE) processes, that are used to form the gatesidewall spacer 30. Further, by limiting the number of epitaxialsemiconductor crystal growth planes that are available, the methods andstructures that are disclosed herein allow for forming a layeredepitaxial semiconductor material 35 c, 35 d, 35 e that includes a bufferlayer portion 35 c, a main portion 35 d and a cap layer portion 35 e. Insome embodiments, by constraining the epitaxial growth so that thesemiconductor material 35 a, 35 b, 35 c, 35 d, 35 e does not extend downthe sidewalls of the fin structures 15 a, 15 b, the methods andstructures disclosed herein may limit the source and drain region togate capacitance.

FIG. 9 depicts another embodiment of an epitaxial semiconductor materialformed in accordance with the present disclosure, in which the epitaxialsemiconductor material includes a buffer layer portion 35 c, a mainportion 35 d, and a cap layer portion 35 e. In the embodiment that isdepicted in FIG. 9, the epitaxial material 35 c, 35 d, 35 e is formed ona recessed surface of a fin structure 15 a. In one embodiment, thebuffer layer portion 35 c has a conformal thickness on the recessedupper surface of the fin structure 15 a, as well as having a conformalthickness on the sidewall portions of the fin structure 15 a that extendfor the upper surface of the fin structure 15 a that has not beenrecessed to the recessed surfaces of the fin structure 15 a. The mainportion 35 d fills the void, i.e., trench, that is formed by recessingthe upper surface of the fin structure 15 a. The cap layer portion 35 eis present atop the main portion 35 d and provides a contact to theepitaxial semiconductor material 35 c, 35 d, 35 e. In one embodiment,the buffer layer would provide a growth nucleation and dopantout-diffusion control (for instance, 20% to 50% germanium (Ge) and 0 to1×10²⁰ atoms/cm³ boron (B)), the main layer would provide channel stressand a high concentration of dopants for out-diffusion (for instance, 30%to 70% germanium (Ge), 2×10²⁰ atoms/cm³ to 2×10²¹ atoms/cm³ boron (B)),and the cap layer provides erosion protection and improved silicidecontact resistance (for instance, 0% to 30% germanium (Ge), 0 to 2×10²⁰atoms/cm³ boron (B)). It is noted that the above example is just onepossible layer structure, as that other layer structures or gradientstructures may also be used in accordance with the present disclosure toprovide the same or other benefits. The epitaxial semiconductor material35 c, 35 d, 35 e may be in the geometry of a source and drain epitaxialmerge structures that extend into contact with adjacent fin structures15 a, 15 b. In another embodiment, each fin structure 15 a, 15 bincludes separate epitaxial semiconductor material 35 c, 35 d, 35 e.

Methods as described herein may be used in the fabrication of integratedcircuit chips. The resulting integrated circuit chips can be distributedby the fabricator in raw wafer form (that is, as a single wafer that hasmultiple unpackaged chips), as a bare die, or in a packaged form. In thelatter case the chip is mounted in a single chip package (such as aplastic carrier, with leads that are affixed to a motherboard or otherhigher level carrier) or in a multichip package (such as a ceramiccarrier that has either or both surface interconnections or buriedinterconnections). In any case the chip is then integrated with otherchips, discrete circuit elements, and/or other signal processing devicesas part of either (a) an intermediate product, such as a motherboard, or(b) an end product. The end product can be any product that includesintegrated circuit chips, ranging from toys and other low-endapplications to advanced computer products having a display, a keyboardor other input device, and a central processor.

While the methods and structures of the present disclosure have beenparticularly shown and described with respect to preferred embodimentsthereof, it will be understood by those skilled in the art that theforegoing and other changes in forms and details may be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended that the present disclosure not be limited to theexact forms and details described and illustrated, but fall within thescope of the appended claims.

What is claimed is:
 1. A method of forming a semiconductor devicecomprising: forming a gate structure on a channel region of a pluralityof fin structures; forming a flowable dielectric material on a sourceregion portion and a drain region portion of the plurality of finstructures, wherein the flowable dielectric material is present at leastbetween adjacent fin structures of the plurality of fin structuresfilling a space between said adjacent fin structures; exposing an uppersurface of the source region portion and the drain region portion of theplurality of fin structures; and forming an epitaxial semiconductormaterial on the upper surface of the source region portion and the drainregion portion of the plurality of fin structures.
 2. The method ofclaim 1, wherein the forming of the gate structure on the channel regionportion of the plurality of fin structures comprises: forming asacrificial gate structure on the channel region of the fin structuresprior to forming the epitaxial semiconductor material; removing thesacrificial gate structure after forming the epitaxial semiconductormaterial; and forming a functional gate structure on the channel regionportion for the plurality of fin structures in the space formed by saidremoving the sacrificial gate structure.
 3. The method of claim 1,wherein prior to said forming the flowable dielectric material, adielectric layer is formed on the source region portion and the drainregion portion of the plurality of fin structures.
 4. The method ofclaim 1, wherein the flowable dielectric material is an oxide.
 5. Themethod of claim 1, wherein the flowable dielectric material is depositedusing spin on glass deposition, flowable chemical vapor deposition(FCVD) or a combination thereof.
 6. The method of claim 1 furthercomprising forming a gate sidewall spacer on sidewalls of the gatestructure after forming the flowable dielectric.
 7. The method of claim3, wherein said exposing the upper surface of the source region portionand the drain region portion of the plurality of fin structurescomprises removing the dielectric layer from the upper surface of thesource region portion and the drain region portion of the plurality finstructures.
 8. The method of claim 1, wherein the forming of theepitaxial semiconductor material on the upper surface of the sourceregion portion and the drain region portion of the plurality of finstructures comprises: forming a silicon and germanium includingsemiconductor material on the source region portion and the drain regionportion of the plurality of fin structures that provide p-type FinFETs;and forming a silicon and carbon including semiconductor material on thesource region portion and the drain region portion of the plurality offin structures that provide n-type FinFETs.
 9. The method of claim 1,wherein epitaxial semiconductor material is an epitaxial semiconductormerge source and drain region structure that extends into contact withadjacent fin structures in the plurality of fin structures.
 10. A methodof forming a semiconductor device comprising: forming a gate structureon a channel region of a plurality of fin structures; forming adielectric layer on a source region portion and a drain region portionof the plurality of fin structures; depositing a flowable dielectricmaterial on the source region portion and the drain region portion ofthe plurality of fin structures over the dielectric layer, wherein theflowable dielectric material is present at least between adjacent finstructures of the plurality of fin structures filling a space betweensaid adjacent fin structures; exposing an upper surface of the sourceregion portion and the drain region portion of the fin structures byetching the dielectric layer; recessing the upper surface of theplurality of fin structures; and forming an epitaxial semiconductormaterial on the upper surface of the source region portion and the drainregion portion of the plurality of fin structures that has beenrecessed.
 11. The method of claim 10, wherein the flowable dielectricmaterial is deposited using spin on glass deposition, flowable chemicalvapor deposition (FCVD) or a combination thereof.
 12. The method ofclaim 10 further comprising forming a gate sidewall spacer on sidewallsof the gate structure after forming the flowable dielectric material.13. The method of claim 10, wherein the forming of the epitaxialsemiconductor material on the upper surface of the source region portionand the drain region portion of the plurality of fin structurescomprises: forming a silicon and germanium including semiconductormaterial on the source region portion and the drain region portion ofthe plurality of fin structures that provide p-type FinFETs; and forminga silicon and carbon including semiconductor material on the sourceregion portion and the drain region portion of the plurality of finstructures that provide n-type FinFETS.
 14. The method of claim 10,wherein epitaxial semiconductor material is an epitaxial semiconductormerge source and drain region structure that extends into contact withadjacent fin structures in the plurality of fin structures.
 15. Asemiconductor device comprising: a gate structure present on a channelregion portion of a plurality of fin structures; a flowable dielectricmaterial present filling the space between adjacent fin structures inthe plurality of fin structures; and epitaxial source and drain mergestructures present on an exposed upper surface of the fin structures,wherein the epitaxial source and drain merge structures extend over theflowable dielectric material that is present filling the space betweenadjacent fin structures.
 16. The semiconductor device of claim 15,wherein the flowable dielectric material is an oxide.
 17. Thesemiconductor device of claim 15, wherein the gate structure includes atleast one gate dielectric and at least one gate conductor.
 18. Thesemiconductor device of claim 15, wherein epitaxial source and drainmerge structures are composed of silicon germanium, silicon doped withcarbon, or a combination thereof.
 19. The semiconductor device of claim15, wherein the upper surface of the plurality of the fin structuresthat the epitaxial source and drain merge structures are present on isrecessed.
 20. The semiconductor device of claim 19, wherein theepitaxial source and drain merge structures comprise a buffer layerportion, a main portion, and a cap layer portion.